CA2198465C - Mulching mower - Google Patents

Mulching mower Download PDF

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Publication number
CA2198465C
CA2198465C CA002198465A CA2198465A CA2198465C CA 2198465 C CA2198465 C CA 2198465C CA 002198465 A CA002198465 A CA 002198465A CA 2198465 A CA2198465 A CA 2198465A CA 2198465 C CA2198465 C CA 2198465C
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CA
Canada
Prior art keywords
cutting chamber
extension
cutting
wedge
mower
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA002198465A
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French (fr)
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CA2198465A1 (en
Inventor
Bart T. Ellson
Jay J. Kakuk
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toro Co
Original Assignee
Toro Co
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Filing date
Publication date
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Publication of CA2198465A1 publication Critical patent/CA2198465A1/en
Application granted granted Critical
Publication of CA2198465C publication Critical patent/CA2198465C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • AHUMAN NECESSITIES
    • A01AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01DHARVESTING; MOWING
    • A01D34/00Mowers; Mowing apparatus of harvesters
    • A01D34/001Accessories not otherwise provided for
    • A01D34/005Mulching means
    • AHUMAN NECESSITIES
    • A01AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01DHARVESTING; MOWING
    • A01D34/00Mowers; Mowing apparatus of harvesters
    • A01D34/01Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus
    • A01D34/412Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters
    • A01D34/63Mowers; Mowing apparatus of harvesters characterised by features relating to the type of cutting apparatus having rotating cutters having cutters rotating about a vertical axis
    • A01D34/81Casings; Housings
    • AHUMAN NECESSITIES
    • A01AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01DHARVESTING; MOWING
    • A01D42/00Mowers convertible to apparatus for purposes other than mowing; Mowers capable of performing operations other than mowing
    • A01D42/005Mulching
    • AHUMAN NECESSITIES
    • A01AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01DHARVESTING; MOWING
    • A01D2101/00Lawn-mowers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S56/00Harvesters
    • Y10S56/17Cutter details

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  • Life Sciences & Earth Sciences (AREA)
  • Environmental Sciences (AREA)
  • Harvester Elements (AREA)

Abstract

A mulching lawn mower has a closed cutting chamber in a mulching mode such that the grass clippings are confined within the cutting chamber except for when they fall out through the open bottom face of the chamber. The cutting chamber has a first portion of toroidal or doughnut form generally closely surrounding the blade tips. In addition, the front portion of the cutting chamber includes a forwardly protruding wedge-shaped extension (48) having side walls (52) that converge towards one another in a pie-shaped fashion. The wedge-shaped extension further includes a top wall (50) that extends between the side walls. This top wall is sloped or inclined downwardly as it extends to the front of the mower such that the height of the wedge-shaped extension gradually decreases until the wedge-shaped extension disappears at its front edge. The wedge-shaped extension reduces power consumption of the mower when the mower is placed in its mulching mode and is used to mulch grass.

Description

2 1 9~4h5 ~ ~'0 g7/0126S PCT/US9G/1092S

HULCHING MOUE~

Terhnical Field This invention relates to a rotary lawn mower having a cutting chamber which is shaped for efficiently mulching the grass clippings while reducing the power consumption of the mower, Back~round of the Invention Hulching lawn mowers are known which direct the grass cllppings severed by the cutting blade downwardly out of the cutting chamber to deposit such clippings in the standing grass remaining in the cut grass path. Various kinds of such mulching mowers are known. For example, mulching mowers are disclosed in U.S. Patents 4,205,512 and 4,951,449 to Thorud, both of which are assigned to the assignee of this invention.
The mulching mowers shown in the Thorud patents have grass deflecting members or kickers within the cutting chamber to assist in the downward movement of the grass clippings. These kickers comprise angled grass A~fl~ctine surfaces that are fixed in each cutting chamber above the plane of the blade. The grass deflecting surfaces are shaped and positioned to intercept the grass clippings as they circulate inside the cutting chamber to redirect such clippings downwardly. The kickers are spaced apart around the circumference of the cutting chamber.
Other mulching mowcrs are known in which no kicker members are present in the cutting chamber. Instead, the cutting chamber and blade are ~pecially shaped to effect mulching. For example, U.S. Patent 3,085,386 to Slemmons discloses a mulching mower having a donut-shaped cutting chamber. A speçially configured cutting blade allegedly causes the grass clippings to be cut in a radial outer portion of the cutting chamber and to be circulated upwardly and inwardly inside the cutting chamber to eventually be driven downwardly out of the cutting chamber through a radial inner portion of the chamber.
Hany mulching mowers known today circulate a fairly signifi~nt halo of grass around the cutting chamber until the grass clippings are driven sussnn~s~Er ~11~26) W O 97~126X 2 ~ 6 5 PCTAUS96/10928 or ~all downward~y out of the cutting chamber, Many of thesc mowers, including the mulching mowers shown in the above-~n~f~ patents, nre powered by internal combustion engines in which power consumption is not generally an issue. Engines of sufficient horsepower are available and can generally be used to allow the grass clippings to he mulched without bogging down.
However, mowers powered by electrical motors, or lower horsepower internal combustion engines, have certain advantages, including tho~e of reduced emissionx. In the field of electrically powered mowers, various mowers have been introduced hnving DC motors powered by self-contained, rechargeable batteries. Some of these mowers use a generally conventionally sha,oed cutting chamber around the blade, namely a cutting chamber that i5 generally circular and closely surrounds the blnde. This cutting chamber can be closed over its top and sides in a mulching mode such that the grass clippings are mulched by being driven downwardly through the open bottom side or face of the cutting chamber.
The power drain on such electrically powered mowers when they are used to mulch is significant. As a practical matter, the batteries may become discharged before the entire lawn or other turf area is mowed.
This requires that the batteries be recharged before the mowing job can be finished, which is obviously inconYenient. Thus, the power consumption of such mowers during mulching, and the consequent reduction in their run time per charge, is a limLtation o~ such a product.

~ -rv of the Invention It i5 one aspect of this invention to proYide a mulching lawn mower that is an efiicient mulcher and exhibits reduced power con.~umption when mulching.
These and other aspects of the invention are provided in a mulching rotary lnwn mower having a cutting blade. A motive means is provided ~or rotating the blade in a plane of rotation about a generally vertical rotational axis. A cutting chamber surrounds ard encloses the cutting blade. over its top and sides when mulching. The cutting chamber has an outer circumferential wall with a lower peripheral edge located belo~ the plane of rotation of the cutting blade. A wedge-shaped extension is provided over n portion of the cutting chamber, the wedge-shaped extension h 5 W O ~7/0126X ' ~ PCTiUS96110~28 being formed in part by a portion of the outer circumferential wall that extends further radially outwardly from a normal orientation thereof and is sloped downwardly as it extends radially outwardly to form an inclined top wall of the extension, Brief DescriDtion of the Drawin~s This invention will be described hereafter in the Detailed Description, taken in conjunction with the following drawings, in which like reference numerals refer to like elements or parts LILLOU~
Fig. 1 is a perspective view of a lawn mower according to this invention, particularly illustrating the mower housing in an exploded form with the plastic deck being separated from the metallic liner;
Fig. 2 is a perspective view of the metallic liner of the mower housing shown in Fig. 1, particularly illustrating the side discharge opening therein for allowing grass clippings to exit through one oi the lateral sides of the cutting chamber and the reinforcement rod placed beneath the side discharge opening to reinforce the liner in that area;
Fi8. 3 is a top plan view of the metallic liner of the mower housing shown in Fig. l;
Fig. 4 is a longitudinal cross-sectional view of the metallic liner of the mower housing taken along lines 4-4 of Fig. 3;
Fig. S is a transverse cross-sectional view of the metallic liner of the mower housing taken along lines 5-5 of Fig. 3; and Fig. 6 is a longitudinal cross-sectional view oi the mower housing shown in Fig. 1 taken along a longitudinal centerline of the mower housi.ng, particularly illustrating the plastic deck and metallic liner in an assembled relatlonship and showing the cutting blade received within the cutting chamber formed in the metallic liner.

Detailed Descrjntion Referring to Fig. 1, the mower 2 of this invention includes a mower housing 4 having a sandwich construction for providing a cost-effective yet strong and durable mower 2. ThLs sandwich construction includes:

SaBSlllUlESHE~ (RUIE26) . .

W O 9710126R 2 ~ q ~ ~ 6 5 PCT~US96/lo92X
a one-piece plastic deck 6, in~ection molded from an inexpensive, 11gh~ig~t plastic material (e.g. high-density polyethylene) t that forms the visible superstructure of mower 2; and a metallic liner 8, stamped from relatively thin steel (e.g. 20 gauge~, that forms tho cutting chambe.r 1~ and is integrally affixed to plastic mower deck 6 to be received within and hidden by plastic mower deck 6.

Deck 6 and liner 8 will be integrally affixed to one another by a plurality of ~tt--l screws 12. When so united to form mower housi.ng 4, the combined weight of deck 6 and liner 8 is quite light, on the order of ten pounds or so.
~ ower housing 4 is supported for movement over the ground by a plurality of rotatable, ground engaging wheels 14, disposed in a pair of front wheels 14f and a pair of rear wheels 14r. Only one front wheel 14f and one rear wheel 14r of oach pair are shown in Fig. 1. The front wheels 14f ure rotatably carried on the opposed ends o~ a front axle 16f, Similarl.y, the rear wheels 14r are rotatably carried on th~
opposed ends of a rear axle 16r. Front and rear axles 16 are supported on mower housing 4 simply by being captured or trapped between deck 6 and liner 8 when those two r~ ,- tc are assembled together to form mower housing 4, as will be described in more detail hereafter.
A motive means 18 is carried on nower housing 4 arranged with its drive shaft 20 extending vertically for rotating a cutting blade 22 within cutting chamber 10 in mower housing 4. Cutting chamber 10 is configured to act as an extremely effective mulcher even with a rel.atively low power motive means 18. Preferably, motive means 18 comprises an electric motor 24, either a DC motor operated by self-contained batteries (not shown) carried in mower housing 4 or an AC
motor operated by an external electrical AC power source (not shown) coupled to the motor by suitable electrical cords (not shown). However, mower 2 of this invention is not limited for use with electrical motors, but may also employ an internal combustlon engine in place of electric motor 24.

SU~ ~6) WO 97101268 ~ 1 ~ 8 4 ~ 5 PCllUS96~10928 Motor 24 is carried on mower housing 4 within a recessed motor compartment 26 provided in plastic deck 6. Deck 6 preferably includes a motor shroud ~not shown) to enclose motor compartment 26 to protect motor 24 and its associated electrical ~ .- q from exposure to the environment. In addition, mower 2 includes a U-shaped handle assembly (not shown) extending upwardly and rearwardly from mower housing 4 to allow mower 2 to be pushed and manipulated by an operator who walks behind mower housing 4. Thus, lawn mower 2 of this invention is of the type commonly known as a walk behind rotary mower.
Referring now to the construction of metallic liner 8, liner 8 includes a generally toroidal or "doughnut" shaped cutting chamber l0 in which the cut grass particles are circulated before they are discharged.
This cutting chamber l0 is formed by various integrally formed walls including an inner CiL~ 'rLr~ltlal wall 28, a relatively horizontal top wall 30, and an outer circumferential wall 32. Inner circumferential wall 28 slopes inwardl.y as it extends downwardly from top wall 30 to its lower end where it joins a ring-shaped motor attachment flange 34.
Inner circumferential wall 28 and motor attachment flange 34 effectively form a pie-shaped recess in the central portion of liner 8. Outer circumferential wall 32 extends generally vertically downwardly from top wall 30 to terminate in a lower peripheral edge 36. Outer circumferential wal l 32 is considerably longer than inner circumferential wall 28 such that Its lower peripheral edge 36 is located below the plane of rotation of cutting blade 22.
The toroidal cutting chamber lO formed in liner 8 is generally flat and of relatively constant cross-sectional shape except for two exceptions. First, a side discharge opening 38 is provided in outer circumferential wall 32 of chamber l0 along one lateral side to allow grass clippings to be. discharged through that opening 38 to the side of mower 2. Plastic deck 6 preferably includes a pivotal flap or cover (not shown) that i5 spring biased to normally cover side discharge opening 38 to close this opening 38 off and to place mower 2 into its mulching mode. In this mulching mode, cutting chamber l0 is efEectively closed over its side.s and its top such that the grass clippings can be discharged only through the open bottom face of cutting chamber l0.
however, if one wishes to discharge the grass to the side rather than to mulch, the flap or cover that normally covers side discharge opening 38 SU~lilUltSllEE~ ~PJIE26) W 0 97/01l68 ~ 1 q ~3 4 6 5 - 6 - PC~US961109~8 can be pivoted upwardly to open side discharge opening 38 in liner 8.
Then, the grass clippings exit through the side of liner 8 and through a side discharge chute to fall directly onto the ground or into a bagging attachment that may be connected to plastic deck 6 in communicati.on with side discharge opening 38.
Side discharge opening 38 extends over a substantial portion oi' the depth of outer circumferential wall 32. This leaves only a small strip 40 of steel remaining in that wall underlying side discharge opening 38. Because this area of liner 8 i8 often impacted with rocks or other debris being circulated in cutting chamber lO, a separate steel or plastic reinforcing rod 42 is attached to liner 8 in that strip area underlying side discharge opening 38 to provide adequate strength and durability. Rod 42 is configured to nest within a portion of an upturne.d lip 44 provided on lower peripheral edge 36 underlying side discharge opening 38. Lip 44 is provided with two tabs 46 that may be bent down to clinch rod 42 in place after rod 42 is nested within lip 44. The tabs are shown in Fig. 2 prior to being clinched downwsrdly over rod 42.
The second exception to the genorally uniform shape of the toroidal cutting chamber is a forwardly extending, wedge-shaped extension 48 provided in liner 8 over a forward portion of cutting chamber 10. Basically, outer circumferential wall 32 of deck 6 is pulled iorwardly over this area and is sloped downwardly as it extends forwardly to form a top wall 50 of extension 48. Triangularly shaped side walls 52 join the sloped top wall 50 of wedge-shepe.d extension 48 to the normal, curved shape of outer circumferential wall 32. Forward wedge-shaped extension 48 decreases in depth as it extends forwardly.
In addition, side walls 52 of forward extension 48 slant inwardly as they extend forwardly such that forward extension 48 also decreases in width.
The purpose of forward wedge-shaped extension 48 is to iorm a space in toroidal cutting chamber lO of expanded volume to allow the grass clippings being circulated in cutting chamber lO to more quickly leave cutting chamber lO and be mulched. Referring to Fig. 4, the normal cross-sectional shape of the toroidal cutting chamber is indicated by the dashed line 54. Thus, wedge-shaped extension 48 comprises that space or volume forward o~ dashed line 54, keeping in ~ W O 971~1268 ~ 1 9 8 4 6 5 PCT/US96/10928 mind that Fi8. 4 is a two-dimensional representation of wedge-shaped extension 48 taken along the longitudinal centerline of mower 2. Wedge-shaped forward extension 48 hss been found by the Applicants to be particularly desirable in improving the mulching efficiency of an electrically powered mower or any mower in which the power available for cutting is a concern.
Referring to Fig. 3, in a mower 2 having a cutting chamber lO with a diameter d of approximately 18 inches, one version of wedge-shaped extension 48 giving good results has a maximum width wl of approximately ll inches tapering inwardly to a minimum width w2 of approximately 7 inches. Referring to Fig. 6, in a mower 2 having a perpendicular distance h of approximately 3.5 inches between lower peripheral. edge 36 and top wall 30, such an extension has a maximum height h at the rear of approximately 2.5 inches and a length l along the base of side wall 52 of approximately 3.75 inches. In general, the Applicants have found that maximizing the volume in extension 48 is desirable within the constraints of size imposed by the dimensions of the forward portion of mower 2.
In addition to cutting chamber lO just described, liner 8 also includes front and rear attachment aprons 56 and 58 integrally formed therewith. Each of the attachment sprons 56, 58 includes a relatively horizontal surface 60 that is spaced a small distance above lower peripheral edge 36 of cutting chamber lO. Each attachment apron 56, 58 includes a plurality of holes 62 through which some of the threaded attachment screws 12 extend when joining liner 8 to plastic deck 6.
Three such holes 62 are spaced across the width of front apron 56. Four such holes 62 are spaced across the width of rear apron 58, two holes 62 in a front row and two holes 62 in a rear row.
Each of the Att- ~ holes 62 in the rear row on rear apron 58 are not formed in the plane of horizontal surface 60 of apron 58 as are holes 62 in the front row. Rather, the rear attachment holes 62 are carried on the front end of forwardly extending fingers 64 that are bent downwardly out of relieved portions of apron 58 such that fingers 64 are parallel to horizontal. surface 60 of apron 58 but are located beneath the relieved apron portions. Each finger 64 includes an arcuate groove 66 located i 'i~tPly rearwardly of each rear att- ' hole 62.
This finger construction forms a convenient way of attaching a WO 9710126X ~ 1 9 ~ 4 ~ 5 8 - PCTiUS96/1092X

traLllng rear shield 68 to mower 2. Shield 68 is molded of a plastic material having a cylindrical upper portion 70 forming a pivot rod.
This cylindrical portion 70 can be received in arcuate grooves 66 on fingers 64 by pushing cylindrical portion 70 rearwardly in the. gap formed between fingers 64 and rear apron 58 until cylindrical portion 70 drops into place in arcuate grooves 66. Trailing rear shield 68 ls provided with slots 72 to allow fingers 64 to pass through the plane of shield 68 during this insertion process. In any event, when tralling rear shield 68 is so installed, shield 68 is free to rotate sround the axis of its cylindrical portion 70, but will be rOEtained on liner 8 by the same two att~-' t screws l2 passing upwardly through attachment holes 62 in fingers 64. Thus, mower 2 need noe have any separate way o~
pivotally attaching trailing rear shield 68 to liner 8 - some oi the same attachment screws 12 that help hold liner 8 to plastic deck 6 retain trailing rear shield 68 in place in arcuate grooves 66 formed in fingers 64.
Turning now to the construction of plastic deck 6, plastic deck 6 is formed to substantially wholly enclose and surround steel llner 8 when the two are united togothcr. Deck 6 includes a recessed motor compartment 26 that has a pie-shapod portion 74 that corresponds in shape to the pie.-shaped central portion o~ liner 8. In addition, motor j t 26 includes a flat floor 76 extending rearwardly {rom pie-shaped portion 74. This flat rear floor 76 of motor compartmont 26 is used as a battery storage area in a mower powered by a DC motor. In any event, when liner 8 and dock 6 are ~oined together, pie-shaped portivn 74 of motor compart~ont 26 nosts within the similarly shaped pie-shaped portion of liner 8 and rear floor 76 of motor compartment 26 abuts against a portion of top wall 30 of liner 8, as shown in Fig. 6.
Plastic deck 6 includes a raised nose portion 78 defLning the front exterior surface of mower 2. ~hen deck 6 and liner 8 are assembled together1 this nose portion 78 is spaced substantially above the front portion of cutting chamber lO. However, a plurality of 1 ~ngi tll~in~l ly extonding ribs 80 are formed on the ~n~nrs-1rfn~e of nose portion 78 ~yt~n~ng downwardly. These ribs 80 have a lower edge shaped to conform to the shape of liner 8 so as to a~vut against various portions of liner 8J One such 1ongit11~in~1 rib 80 is shown in Fig. 6 abutting against a portion of top wall 30 of liner 8 and wedge-shaped ~ W O 97101268 ~ i 6 5 PCTiU~g6~lV928 extension 48 o~ cutting chamber 10. In addition, similar longitudinsl ribs 81 can extend downwardly from rear floor 76 of plastic deck 6 to engage against the rear portion of cutting chamber 10 and rear apron 58 in selected portions thereof. Transverse ribs ~not shown) can also extend downwardly from the underside of deck 6 to engage against lateral portions of cutting chamber 10.
The underside of plastic deck 6 is also formed with a plurality of downwardly extending bosses 82 each having an interior bore with screw 12 being self-threading when screwed into such bores. These various bosses 82 are aligned with attachment holes 62 in liner 8 when deck 6 is superimposed on liner 8. Thus, the various attachment screws 12 can extend upwardly through attachment holes 62 in liner 8 to be threaded into bosses 82 on deck 6 to firmly and rigidly secure deck 6 to liner 8.
In addition to attachment holes 62 provided on the front and rear aprons of liner 8 as described previously, various other attachment holes 60 can be provided on top wall 30 of cutting chamber 10 to be mated with other bosses (not shown) on deck 6.
As previously described, wheels 14 used to support mower housing 4 are carried on the opposed ends of front and rear steel axles 16. Axles 16 are conveniently formed as separate - ,-. . Some of the ribs 80, 81 on the underside of deck 6, as well as the side walls of deck 6, are formed with arcuate bearing surfaces 84 in which axles 16 are received.
Axles 16 are mereLy placed into sucb bearing surfaces 84 before liner 8 is joined to deck 6. When liner 8 is then screwed to deck 6, the front and rear aprons 56, 58 thereon hold axles 16 in place in deck 6, i.e.
axles 16 are captured or trapped between arcuate bearing surfaces 84 in deck 6 and the front and rear aprons of liner 8 Thus, axles 16 are easily and inGA~ iv~ly mcunted on mower housing 4 due to the sandwich construction comprising deck 6 and liner 8.
Each axle 16 includes an integrally formed circular ring 86 thereon. At least some of arcuate bearing surfaces 84 formed in deck 6 are spaced apart by a distance slightly greater than the thickness of ring 86 to allow ring 86 to be received therein. In addition, the front and rear aprons on liner 8 sre esch provided with a slot 88 for receiving a bottom portion of ring 86 when deck 6 and liner 8 are assembled together. This ring 86 and its described ~nga~ t with deck 6 and liner 8 prevent substantial lateral movement of axle 16 relative SUlSmUlESllEEr (RUIE26) W~ 97101268 ~ 4 h 5 P~,T~1~96/10928 to mower housing 4 to prevent wheels 14 from engaging against the sidcs of mower housing 4.
Each axle 16 is normally fixed in place on mower housing 4 through a height of cut adjustment moch~ni ~m which will be described next.
However, axles 16 are ~ree to rotate relative to mower housing 4 during a height of cut ad~ustment operation to vary the position of wheel.s 14 relative to the housing. Thus, while the deck and liner construction sandwiches or traps axles 16 therebetween, they are not trapped so tightly that they cannot rot&te during a height of cut adjustment operation~ t!owever~ once the height of cut is set to a desired value and that adjustment is locked in place, axles 16 are then non-rotatably fixed to mower housing 4 during normal operation of mower 2.
Conventional height of cut ad~ustment '~i are provided for changing the height of mower housing 4 relative to the ground. These include a height of cut lever 89 formed as a spring arm which is clamped or fixed to each axle 16 using the same pivot bolt that rotatably ~ournals one of wheels 14 to axle 16. Each height of cut lever 8g carries a pin or button 90 which is received in one of a plurality of locking recesses 9Y formed in an arcuate array. The spring bias in lever 89 is normally in the direction that keeps locking pin 90 engaged with one of locking recesses 92 in the array thereof. Howevor, when it is desired to change the height of cut, the operator need only pull outwardly on lever 89 to disengage pin 90 from a first recess 92, to then rotate axle 16 using height of cut lever 89 until pin 90 thereon is alignsd with a different recess 92, and to then release height of cut lever 89 to allow the. bias therein to force pin 90 into the new recess 92, thus changing the orientation of wheels 14 relative to mower hou~ing 4 to adjust the height of mower housing 4 relative to the ground.
Locking recesses 92 for the front height of cut lever 89 can simply be molded into one side wall of plastic deck 6 as only 1~3 of the weight carried on deck 6 is at the front of mower 2. However, a separate steel plate 94 is used for providing locking recesses 92 on the rear of mower 2, where the batteries are stored, to coact with the rear height of cut lever 89 since 2/3 of the mower's weight is at the roar of nower 2. This plate 94 can simply be inserted into a slot in a recess 96 formed therefor in the side wall of deck 6 with plate 94 again being clamped between deck 6 and liner 8 when the two are assembled together.

S~SIIIUIESHEI (RUIE26) ~ WO g7/0l268 2 1 J 8 4 6 5 PCT/US96/10928 In this regard, rear apron ~8 of liner 8 has an upturned side lip 100 for engaging against the outside of the bottom of plate 94 when plate 94 is clamped in place by liner 8. Locking recesses 92 at the front and rear of mower 2 and their corresponding height of cut levers 89 are desirably provided on only one side of plastic deck 6.
The Applicants have found that mower housing 4 formed by an upper plastic deck 6 and a fixedly attached steel liner 8 is inexpensive to produce but very rigid and durable during operation. Steel liner 8 withstands impacts from rocks and other debris and is not prone to being chipped or damaged during use o~ mower 2. Plastic deck 6 can be inexpensively formed from a less expensive plastic and united to steel liner 8, providing a mower housing 4 which is less expensive than one which is cast from aluminum or one made from a plastic of sufficient durability that it could be used to form cutting chamber 10. The nested configuration of the pie-shaped portions of deck 6 and liner 8, the abutment of the various surfaces therebetween, the use of the front and rear ~tt~ t aprons on liner 8, all provide a liner 8 which can be easily attached to plastic deck 6 and which rigidifies plastic deck 6 to a substantial degree.
Another advantage of this sandwich construction is the ability to conveniently and simply support some of the other components of mower 2 between deck 6 and liner 8, or on liner 8, when deck 6 and liner 8 are ~oined together. For example, the front and rear axles 16 are simply trapped or captured between arcuate bearing surfaces 84 therefor as formed in deck 6 and portions of liner 8 and are retained in place simply by securing liner 8 to deck 6. Similarly, trailing rear shield 68 simply hangs from a portion of liner 8 and is retained in place by some of the same attachment screws 12 which join deck 6 and liner 8 together. This contributes to the cost effectiveness of mower housing 4.
In addition, it is possible to easily change the styling or look of mower 2, or to have different looks for different models of mowers, simply by having differently shaped plastic decks 6 that can be joined to a common liner 8. Again, this contributes to manufacturing efficiency and to the cost effectiveness of mower 2.
As noted previously and as shown in Fig. 6, mower 2 is preferably equipped with a DC motor. One such motor that can be used is a 24V D~

W O 97/01268 '~ l q g ~ ~ 5 PCT/US9~/10~28 motor having approximately 0.68 peak horsepower, though a 36V DC motor could also be used. Hotor 24 Is received in the central portion of mower housing 4 and specifically in the nested pie-shapod portions o~
plastic deck 6 and liner 8. Motor 24 includes a flat ~ttr ' ' bracket 102 on the bottom theroof which rosts on a ring 104 carried at the bottom of pie-shaped portion Y4 on plastic deck 6. A plurality of bolts extend up through motor attachment ilange 34 on linsr 8 and through ring 104 on deck 6 to bolt electric motor 24 in place.
Electric motor 24 includes a vertically downwardly extending drive shait 20. The lower end o~ drive shaft 20 includss an internally threaded bore. A bushing 106 is received around drive sh~ft 20 and a bolt 108 is used to clamp cutting blade 22 against the bottom of bushing 106, bolt 108 being threaded into and tightened in the bore on the lower end of drive shaft 20. A fan 110 is not-rotatably received on bushing 106, e.g. by a polygonal fit between thc two, to rotate with bushing 106 and hence with blade 22. Fan 110 helps cool electric motor 24.
Cutting blade 22 received in cutting chamber 10 includes a relatively flat central portion 112 and downwardly sloped radial outer portions 114. Each radial outer portion includes an upturned sail 116 at its radially outer end along the trailing edge of blade 22, tipped up at 15~ relative to the horizontal. A sharpened cutting edge 11~ is located in the downwardly sloped outer blade portions 114 along the leading blade edge which cutting edge 118 has a length generally equal to or slightly less than the normal cross sectional width ~f toroidal cutting chamber 10. As blade 22 is rotated by operation of motor 24 in a generally horizontal cutting plane, cutting edges 118 sever grass and circulate the cut grass clippings in cutting chamber 10 in the direction of rotation of the blade. Basically, the grass clippings form a rotating mass or halo of clippings c.arried in cutting chamber 10.
The Applicants have found that use of the forwardly o~t~n~ing wedge-shaped extension 48 of cutting chamber 10 significantly reduces the power consumption of an electrically powered mower. This is thought to be due to tne relative quickness in which the clippings exit cueting chaober 10. Rather than continually circulating the clippings in a large mass around and around cutting chamber 10 until they fall. out of the open bottom face of cutting chamber 10, the clippings more quickly fall out of cutting abamber 10 when they reach wedge-shaped extension 48 ~ W O 97/012C8 2 1 9 ~ 4 6 5 pcTrus96llo928 and the expanded volume contained therein. This is assisted by the downward slope of top wall 50 of extension 48 which mechanically deflects the clippings downwardly out of cutting chamber 10 and into the grass. While some of the clippings may be picked up and recut again when mower 2 passes over them since they are deposited in advance of cutting blade 22, at least some will be hidden in the grass after their first pass through wedge-shaped extension 48. Thus, the blade does not have to circulate as larg~ a mass of clippings as it would if wedge-shaped extension 48 were absent and the front of cutting chamber 10 had the same cross-sectional toroidal shape as the rest of cutting chamber 10 .
The practical effect of this wedge-shaped extension 48 of cutting chamber 10 is that the amperage draw on electric motor 24 is considerably less than in a mower without this extension. In a battery powered mower having a DC motor 24, this translates into a longer ru~
time for mower 2 given the same battery charge. This is a significant advantage.
The Applicants have tested a mower 2 of this invention having forward wedge-shaped extension 48 powered by a 24V DC motor against a competitive electrically powered mower utili7ing a similar 24V DC motor and battery power. In a test of free run time, i.e. how long a full charge will be depleted by operation of the motor while running freely without cutting grass, the mower 2 of this invention had an average free run time of 114 minutes versus an average free run time of 100 minutes for the competitive mower However, in a test of run time while cutting 1 inch of grass and mulching the clippings, the run time of mower 2 decreased to an average of 79 minutes while the run time of the competitive mower decreased to an average of 47 minutes. Thus, the run time of mower 2 decreased only approximately 30X from its free run time while mulching while the run time of the competitive mower 2 decreased approximately 53X while mulching in similar conditions. Mower 2 can simply run longer while mulching than a similar competitive mower due to the use of wedge-shaped extension 48.
Wedge-shaped extension 48 is shown as being located ae the front of cutting chamber 10 and extending forwardly therefrom. This allows the grass clippings to be mulched down into the grass in advance of cutting blade 22. Longer clippings which are not hidden well in the SUBS~E ~Er aWE ~) .. . . . .. .... . . _ ... .. _ . .. ... . . . . _ _ _ _ _ _ _ _ 21~465 W O 97/01268 rCTn~996/l0~28 grass will be picked up again when the blade passes over them and recut, further enhancing the mulching effectiveness of mower 2.
however, much of the dccrea~e in power consumpeion exhibited by use of wedge-shaped extension 48 is thought to be due simply to its ability to more quickly allow the clippings to exit from the otherwise generally closed cutting chamber 10. In thia regard, placement of wedge-sh~ped extension 48 towards the front of cutting chamber 10 is not critical. It could as well extend rearwardly from the rear of cutting chamber 10.
Various other modifications of this inveneion will be apparent to those skilled in the art. For example, if an AC motor ia placed wi.thi.n motor compartment 26, the actual motor 26 can be placed over floor 76 and a belt transmission can be used to drive a blade spindle mounted in the pie-shaped portion 74 of deck 6. In addition, while use of an electric motor 24 in conjunction with wedge-shaped extension 48 of cutting chamber 10 is particularly effective, a cutting chamber with such an extension will also increase the mulching effec~ivenesa of a mower powered by a gasoline engine, particularly by such engines h~ving lower power. Accordingly, the ~cope of this lnvention is to be limited only the appended claims.

~mu ES~

Claims (12)

CLAIMS:
1. A mulching rotary lawn mower, which comprises:
(a) a cutting blade;
(b) a motive means for rotating the blade in a plane of rotation about a generally vertical rotational axis;
(c) a cutting chamber for surrounding and enclosing the cutting blade over its top and sides when mulching, the cutting chamber having an outer circumferential wall with a lower peripheral edge located below the plane of rotation of the cutting blade; and (d) a wedge-shaped extension provided over a portion of the cutting chamber, the wedge-shaped extension being formed in part by a portion of the outer circumferential wall that extends further radially outwardly from a normal orientation thereof and is sloped downwardly as it extends radially outwardly to form an inclined top wall of the extension, wherein the wedge-shaped extension is an integral continuation of the cutting chamber.
2. A lawn mower as recited in claim 1, wherein the wedge-shaped extension is provided over a forward portion of the cutting chamber such that the inclined top wall of the extension is located in advance of the cutting blade.
3. A lawn mower as recited in claim 2, wherein the wedge-shaped extension further includes side walls for joining either side of the top wall of the extension to the outer circumferential wall, wherein the side walls of the extension taper inwardly as they extend forwardly such that the top wall of the extension decreases in width as it extends forwardly.
4. A lawn mower as recited in claim 3, wherein a forwardmost edge of the top wall is located approximately at the same level as the lowermost peripheral edge of the circumferential wall such that the wedge-shaped extension decreases in height from a maximum value at a rear side thereof to approximately zero at the forwardmost edge thereof.
5. A mulching rotary lawn mower, which comprises:
(a) a cutting blade;
(b) a motive means for rotating the blade in a plane of rotation about a generally vertical rotational axis;
(c) a cutting chamber, movably supported by a plurality of ground engaging wheels, for surrounding and enclosing the cutting blade over its top and sides when mulching, the cutting chamber being generally toroidal in form; and (d) a forwardly extending, wedge-shaped extension provided over a forward portion of the cutting chamber, the wedge-shaped extension decreasing in height from its junction with the cutting chamber as it extends forwardly, the junction between the extension and the cutting chamber being substantially unobstructed.
6. A mulching rotary lawn mower, which comprises:
(a) a cutting blade;
(b) a motive means for rotating the blade in a plane of rotation about a generally vertical rotational axis;
(c) a cutting chamber, movably supported by a plurality of ground engaging wheels, for surrounding and enclosing the cutting blade over its top and sides when mulching, the cutting chamber being generally toroidal in form; and (d) a forwardly extending, wedge-shaped extension provided over a forward portion of the cutting chamber, the wedge shaped extension decreasing in width from its junction with the cutting chamber as it extends forwardly, the junction between the extension and the cutting chamber being substantially unobstructed.
7. A mulching rotary lawn mower, which comprises:
(a) at least one cutting chamber, movably supported by a plurality of ground engaging wheels, which is generally enclosed in a mulching mode thereof to confine severed grass clippings within the cutting chamber until such time as the grass clippings exit the cutting chamber through an open bottom side of the cutting chamber;
(b) a cutting blade contained within the cutting chamber;
(c) a motive means for rotating the blade about a generally vertical rotational axis thereby establishing a generally horizontal cutting plane within the cutting chamber; and (d) wherein the cutting chamber includes a radially outwardly protruding extension that mates with the cutting chamber over a junction that is substantially unobstructed which junction also extends over a majority of the height of the cutting chamber such that grass clippings can freely flow from the cutting chamber into the extension.
8. A lawn mower as recited in claim 7, wherein the extension has a decreasing height as it protrudes radially outwardly.
9. A lawn mower as recited in claim 7, wherein the extension has a decreasing width as it protrudes radially outwardly.
10. A lawn mower as recited in claim 7, further including a pair of front wheels and a pair of rear wheels for movably supporting the cutting chamber, and wherein the extension extends radially forwardly between the pair of front wheels.
11. A lawn mower as recited in claim 7, wherein the motive means comprises an electrical motor.
12. A lawn mower as recited in claim 11, further including rechargeable battery means carried on the mower for powering the electrical motor.
CA002198465A 1995-06-26 1996-06-26 Mulching mower Expired - Fee Related CA2198465C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US08/494,436 1995-06-26
US08/494,436 US5638667A (en) 1995-06-26 1995-06-26 Mulching mower
PCT/US1996/010928 WO1997001268A1 (en) 1995-06-26 1996-06-26 Mulching mower

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CA2198465A1 CA2198465A1 (en) 1997-01-16
CA2198465C true CA2198465C (en) 2000-08-22

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AU (1) AU697206B2 (en)
CA (1) CA2198465C (en)
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WO (1) WO1997001268A1 (en)

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Also Published As

Publication number Publication date
US5638667A (en) 1997-06-17
AU697206B2 (en) 1998-10-01
WO1997001268A1 (en) 1997-01-16
DE69610281D1 (en) 2000-10-19
AU6291596A (en) 1997-01-30
EP0784419B1 (en) 2000-09-13
EP0784419A1 (en) 1997-07-23
CA2198465A1 (en) 1997-01-16
DE69610281T2 (en) 2001-04-12

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